I think the artifacts in the minifig-heads pic are induced by bugs and not by the limits of crease-angles, because there appears to be flat-shading errors at very low angles (e.g. nearly smooth sides). But it is also possible that the meshes aren't manifold or contain tiny cracks that throw your code off.

Could you post a screenshot of parts 6085.dat with the crease-angle smoothing? If I understand, it may look weirdly rounded due to the soft angles.

Also, how are you handling BFC? Does your algorithm assume BFC or cope with the case where the winding order of adjacent triangles is opposite (thus inducing opposite normals)?

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